MV Agusta 2008 F4 312RR 1078 Workshop Manual
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MV Agusta 2008 F4 312RR 1078 Workshop Manual

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  • Page 2 ©2008 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part. N°8A00B2576 - Edition N°1 Printed – October 2008...
  • Page 3 Workshop engine manual MV AGUSTA F4 312RR 1078...
  • Page 4 Everything that we do has repercussions on the entire planet and its resources. MV Agusta, wanting to protect the interest of the people, would like to make the client and the technicians of the technical assistance centres aware and to adopt modalities of use of the motorcycle and the disposure of its parts in full respect of the norms in force in terms of environmental pollution, disposal and the recycling of waste.
  • Page 5 Freni General Index GENERAL DESCRIPTION ..................MAINTENANCE ......................CYLINDER KIT ......................CRANKCASE ......................LUBRICATION........................ ELECTRICAL COMPONENTS ..................TIGHTENING TORQUES ....................SPECIAL TOOLS ......................ANALYTICAL INDEX ....................- 3 -...
  • Page 7 General description SECTION Revision 0 - 1 -...

  • Page 8: Table Of Contents

    General description SUMMARY HOW TO CONSULT THIS MANUAL ........... . .PAGE 3 THE PURPOSE OF THIS MANUAL .

  • Page 9: How To Consult This Manual

    All information, instructions and technical data included in this manual are based upon information on the product updated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment with- out prior notice and without incurring any obligation.

  • Page 10: Glossary And Symbols

    General description GLOSSARY AND SYMBOLS During this kind of proce- All of the countersigns indicting right, N.B. ATTENTION dure inflammable vapours left, superior, inferior, front and back, might develop and metallic refer to the motor-bike in the normal parts might be expelled at direction of march.
  • Page 11 General description Use the recommended sealant. Use the recommended oil. Use the recommended adhesive. Use the recommended grease. Carry out accurate cleaning. Use the recommended brake fluid. Use the recommended suspension fluid. Use new components. Use the recommended coolant. Substitute the component. Use the recommended thread-locking Do not leave litter about.

  • Page 12: Right Hand And Left Hand Standard

    General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Cylinder 3 Cylinder 2 Cylinder 4...

  • Page 13: Safety

    General description SAFETY The information contained in this paragraph is fundamental so that the operations carried ATTENTION out on the motorcycle can be conducted with minimum risk to the mechanic. Carbon Monoxide • Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of con- sciousness and death.
  • Page 14 General description Brake fluid • Brake fluid is extremely corrosive. • Avoid any contacts with the eyes, skin and the mucous membrane. • If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap and water.

  • Page 15: Index

    • Slackening or tightening nuts or screws, always start with those of a greater dimension or from the centre. Always respect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...

  • Page 16: Operative Technical Specifications

    General description OPERATIVE TECHNICAL SPECIFICATIONS MOTORCYCLE IDENTIFICATION The registration number of the motorcycle is stamped on the right side of the steering head. The engine registration number is stamped on the upper engine casing, near the forks. 2) Engine registration number 3) Homologation date 1) Frame registration number Below is an example of the designation of the frame registration number:...
  • Page 17 Maintenance SECTION Revision 0 - 1 -...
  • Page 18 Maintenance SUMMARY PLANNED MAINTENANCE SCHEDULE ....................PAGE 3 ADJUSTMENT AND CALIBRATION OF THROTTLE BODY ..............PAG.11 - 2 -...
  • Page 19 Let us help protect the environment Everything we do affects the entire planet and its resources. To protect the common interest, MV Agusta urges its customers and service operators to use the vehicles and dispose of their components in compli- ance with applicable regulations on environmental pollution control, waste disposal and recycling.
  • Page 20 Maintenance 1000 6000 12000 18000 24000 30000 36000 Frequency Km (mi) (600) (3800) (7500) (11200) (14900) (18600) (22400) Pre-delivery- Coupon Description Procedure ● ● ● ● ● ● ● ● Check / Regulation Transmissions and flexible controls ● ● ● ●...
  • Page 21 MOTUL CHAIN LUBE ROAD – * : MV Agusta recommends purchasing the product from its authorized dealers. The engine oil AGIP Racing 4T 10W/60 has been specially designed for the F4 engine. Should this lubricant be unavailable, MV Agusta rec- ommends using fully synthetic oils complying with or exceeding the following specifications: –...
  • Page 22 Maintenance STANDARD ITEM WEAR LIMIT VALVES Ø Sealing external diameter +0,3 24,6 Exhaust......+0,3 28,6 Inlet........+0,2 Sealing face thickness..-0,3 Stem-guide clearance 0,02 ÷ 0,04 mm......Exhaust......Coupling : 0,10 mm 0,01 ÷ 0.03 mm......Inlet........0,08 mm mm......Ø...
  • Page 23 Maintenance STANDARD ITEM WEAR LIMIT CYLINDER AND PISTON ........... Piston ovalization....0,015 mm 0,038 ÷ 0,067 mm Piston-cylinder play....0,10 mm 0,004 ÷ 0,012 mm Piston-pin play....... 0,03 mm 0,015 ÷ 0,032 mm Pin-foot connecting rod play..0,06 mm Segment thickness -0,01 mm......
  • Page 24 Maintenance STANDARD ITEM WEAR LIMIT GEAR SHIFT 0,35 ÷ 0,15 mm......Gear fork-groove pivot play..0,65 mm 7,05 ÷ 7,15 mm....... Drum pit width......7,35 mm 6,8 ÷ 6,9 mm......Ø fork pivot......6,7 mm Minimum idle gear 0,10 mm axial play.........
  • Page 25 Maintenance Cleaning the parts All of the parts must be cleaned with special biodegradable solvents and dried with compressed air. Proceed with the cleaning process of all the parts before disassembling them as well as after the partic- ular parts have been disassembled. Clean each part even before reassembling.
  • Page 26 Maintenance Measuring compression in the cylinder The following tools are necessary in order to carry out this procedure: Spark plug key: n° 800089013 Compression measurer Adapter for the compression measurer. A)Heat the motor to the usual functioning temperature (of regime); B)Turn the motor off, remove covering structure, tank, air box and remove the spark plugs;...
  • Page 27 Maintenance ADJUSTMENT AND CALIBRATION OF THROTTLE BODY After connecting the diagnostic software to the central unit, before starting the engine check the position of the throttle valve: 2.33 degrees (min. 2.1, max 2.5). If it does not fall within the range, use the TPS feature to reset it, WITHOUT TOUCHING THE MECHANIC ADJUSTING SCREW OF THE THROTTLE.
  • Page 28 Maintenance Twist off the plugs that close the vacuum tubes. The number of the cylinder to which the rubber plug is con- nected is written on the plug itself (A). The vacuum tubes are located on the right and left side of the vehicle.
  • Page 29 Maintenance To align the throttle body, use the diagnostic software. For the engine to work properly, adjust the throttle body so that the idling regime control works at “mid-range”. To do this, after finding the correct alignment, proceed as follows: If the “lead correction”...
  • Page 30 Maintenance - 14 -...
  • Page 31 Cylinder kit SECTION Revision 0 - 1 -...
  • Page 32 Cylinder kit SUMMARY CYLINDER HEAD ............................ PAGE 3 DISTRIBUTION CONTROL UNITS ......................PAGE 7 CYLINDER AND PISTON UNIT ......................PAGE 27 - 2 -...

  • Page 33: Cylinder Head

    Cylinder kit CYLINDER HEAD Tightening torque N·m Thread blockers Medium Sealant See text. Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 34 Cylinder kit Removal of Head group Remove the eight tightening nuts (1) and remove the valve cover (2) proceed carefully so as not to damage the gasket (3). When refitting, it is essential to apply silico- ne sealant as shown in the figure at the beginning of the chapter.
  • Page 35 Cylinder kit Remove the oil tube adduction and the head situated at the front of the motor, using the two tightening screw with a T number 8 key. Working on the phonic wheel knot with a number 19 mm bush key rotate the drive shaft up to the point where the n°...
  • Page 36 Cylinder kit Loosen the central screws of the chain tensioner distri- bution system. Remove the chain tensioner by means of the two tightening screws. First remove the 2 external stands (4 and 5) of the camshafts by means of the four screws each internally hexagonal.
  • Page 37 Cylinder kit DISTRIBUTION CONTROL UNITS NORDLOCK detail Tightening torque N·m Tipo Thread blockers Strong Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 7 -...
  • Page 38 Cylinder kit Phase sensor The F4 1078 MVAgusta vehicle is equipped with a phase sensor that transmits timing phase data to the control unit. The discharge side of the camshaft fea- tures a half-ring, the position of which is detected by a sensor which sends information on its timing to the central unit in real time.
  • Page 39 Cylinder kit Remove the 12 tightening nuts from the head begin- ning from the external ones proceeding towards the internal ones, following the sequence indicated in the figure. On each encarcement there is a washer. Be carefully no to let it fall into the motor, you may block the holes with clean rags.
  • Page 40 Cylinder kit Remove the head and place it onto a clear place Remove the gasket which will be substituted during reassembly. Avoid placing the head upside down. Inspection of the head group Remove carbon deposits from the combustion cham- bers. Clean away eventual encrustments from the canalizations of the cooling liquid.
  • Page 41 Cylinder kit Head assy assembly To execute this operation you need the following spe- cial tool: A) n° 8000A3406 piston / cylinder plane distance measuring tool Place the new gasket on the cylinder plane. The gasket is of the same thickness of the one instal- led before if no parts replacement occurred.
  • Page 42 Cylinder kit Fit the gasket with the inscriptions facing up and the protrusion towards the march gear. Insert the centering bushes between the head and the cylinder. Insert the washers on the encarcement if 35 N•m necessary with the help of a screw driver to guide them onto the internal encarcements.
  • Page 43 Cylinder kit Continue with the setting as follows: be sure that piston n° 1 is the MSP in burst phase; in this position “T” notch on the phonic wheel is in line with the reference notch on the bedplate. Remove the copper thread from distribution chain, keep the chain tightened.
  • Page 44 Cylinder kit Pin number 1 Pin number 24 Pin number 25 - 14 -...
  • Page 45 Cylinder kit Insert the inlet camshaft so that the phase notch on the conveyer wheel is parallel to the head plane and facing the outside. Insert the exhaust camshaft with the notch placed bet- ween the 24th and 25th chain distribution gudgeon, beginning to count from gudgeon after the inlet cams- haft notch.
  • Page 46 Cylinder kit Progressively move the internal hexagonal screws 8 N•m close. Tighten the screws at a torque of 12 N·m., always beginning from n°2 and n°3 stands. Check to be sure that the valve cap gaskets are in good condition. Apply a layer of gasket 5552 silicone on the semi moons on the head in correspondence with the cams- haft.
  • Page 47 Cylinder kit Valve removal A)Take out the cups (1) with the help of a magnet and number them with a marker so as to reassemble them in the same position. B)Remove the tablets (2) of play adjustment with a magnet and place them inside the relative cup so as to reassemble them in the same position.
  • Page 48 Cylinder kit 800094798 - 18 -...
  • Page 49 Cylinder kit Maintenance of the valve slot Check the stroke surface [A] between the valve [B] and the slot [C] : no traces of pitting or cracks must appear. Measure the external diameter [D] of the stroke surface on the valve slot. If this should appear to be too elevated it is possible to repair the slot.
  • Page 50 Cylinder kit Substitution of the valve slot The following tools are necessary for this procedure: prick-puncher n° 800095319 for inlet slot prick-puncher n° 800095318 for exhaust slot Proceed as follows: A)Remove the worn slots carefully milling them so as not to damage the head lodging B)Check the lodging diameter on the head and choo- se the oversized valve slot considering that the assembling interference should be 0,10÷0,15...
  • Page 51 Cylinder kit Valve guide check and maintenance 800095429 In order to carry out this procedure the following tools are necessary: Control tampon n° 800095429 Tampon n° 8000A2385 valve stem-valve guide play: 0,01÷0,03 mm inlet 0,02÷0,04 mm exhaust coupling limit : 0,08 mm inlet 0,1 mm exhaust internal guide Ø...
  • Page 52 Cylinder kit Guide valve installation Assemble an oversized valve guide as follows: Oil the external valve guide surface. Slowly and evenly heat the cylinder head up to 150°. If necessary cool the valve guides with (N2) nitrogen liquid; or dry ice. Insert the valve guide using the special n°...
  • Page 53 Cylinder kit Valve-guide valve coupling Coupling play at assembly must be: 0,01 ÷ 0,03 mm inlet 0,02 ÷ 0,04 mm exhaust The maximum coupling limit permitted is even to 0,08 mm inlet 0,10 mm exhaust If a major play should result, substitute valve and valve guide.
  • Page 54 Cylinder kit Assembling the valve. 800095180 Insert in the order of: A)Insert the two coaxial springs B)Slide the semi cones into the superior disk slot and thus place the disk on the springs C)Assemble the head on the disassembling valve tool n°...
  • Page 55 Cylinder kit Regulating valve play Verify that the spark plugs have been disassembled. Should this procedure be carried out with the head assembled on the motor, block the spark plug holes with clean rags and assem- ble plate n° 800094797 to avoid the pieces accidentally falling into the chain distributi- on opening.
  • Page 56 Cylinder kit Chain tensioner 8 N•m Remove the central screw-cap and withdraw the spring and the pin. Remove the screws fixing the chain tensioner to the head. Remove the chain tensioner. Disassembly the chain tensioner and check the correct working of each part. The internal pin must run clearly and the inner spring must give a quick response.
  • Page 57 Cylinder kit CYLINDER AND PISTON GROUP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 27 -...
  • Page 58 Cylinder kit Removing cylinder and pistons Remove the cylinder head and rubber connecting rod between the cylinder and water pump as described in the relative paragraphs. Carefully slide out the cylinder group being careful not to damage the elastic strips. Work on one piston at a time to continue the removal.
  • Page 59 Cylinder kit Cylinder revision Check to be sure that enclosures show no sign of sei- zures with the pistons. Check piston ovalization in the following way: A)Measure the nominal diameter of each cylinder at a distance of 20 mm from the superior edge as indicated in the figure.
  • Page 60 Cylinder kit Piston-cylinder coupling The cylinder-piston groups are furnished already cou- pled; if there should be an exchange of cylinders and pistons between them it would be necessary to pro- ceed surveying coupling plays. Measure the diameter of the (ND) pipe at 20 mm from the superior plane, as indicated on the sketch.
  • Page 61 Cylinder kit Piston-pin connecting rod foot coupling Play between piston pin and connecting rod foot must be of 0,015÷0,032 mm. Maximum wear limit allowed 0,06 mm. Segments Verify the absence of lines and traces of shrinkage on each segment. Verify that the edge of the segment is well defined and free in the segments.
  • Page 62 Cylinder kit Cylinder and piston assembly The segments must be assembled on the piston with the writing R RN turned upwards and by following the outline in the figure. Oil the connecting rod foot and piston pin. Assemble the internal ring on the piston Insert the pistons complete with segments on the connecting rods with the arrow facing the exhaust Insert the piston pins into the piston until beat.
  • Page 63 Crankcase SECTION Revision 0 - 1 -...
  • Page 64 Crankcase SUMMARY CLUTCH ..............................PAGE 3 GEAR AND GEAR CONTROL ......................PAGE 12 WATER PUMP ............................PAGE 19 STARTING ..............................PAGE 24 ENGINE BLOCK............................PAGE 26 COVERS..............................PAGE 27 MAINSHAFT ............................. PAGE 37 - 2 -...

  • Page 65: Clutch

    Crankcase CLUTCH 1 code 8000A6917 q.ty 2 2 code 8000A6916 q.ty 7 3 code 8000A6918 q.ty 9 4 code 8000A6915 q.ty 1 5 code 8000A6922 q.ty 1 6 code 8000A6923 q.ty 1 Engine side Engine side Tightening torque N·m Thread blockers Strong Apply motor oil Apply silicone sealing...
  • Page 66 Crankcase The clutch release occurs using a postponing return group composed of a small thrust piston placed on the left side of the motor and operated by a hydraulic sys- tem. This small piston pushes a command rod which makes the disk pusher plate function.
  • Page 67 Crankcase To avoid damaging oil seal (1) (see the diagram on the next page), if the clutch rod should come out, be sure to refit it from the clutch control cylinder side (right side of the engine), with the lubrica- tion groove facing the clutch.
  • Page 68 Crankcase Remove the spacer (6) and the grazer washer (7). Disassemble the clutch block following the sequence in the figure. - 6 -...
  • Page 69 Crankcase Clutch overhauling Check the rod for straightness and wear. Check the friction plates for wear. The standard thick- ness is 3 mm Maximum allowed wear limit : 2,8 mm. No signs of burning, grooves or other damages are allowed. Replace the whole plates group even if only one is damaged.
  • Page 70 Crankcase Clutch reassembly Reposition the thrust washer with the smaller diameter facing the engine. Fit the spacer, the roller cage, the clutch drum and the washer. Since the washer in front of the clutch drum is obtained by blanking, it has a sharp edge and a rounded edge.
  • Page 71 Crankcase Use the tool no. 800079015 to lock the clutch bell, then tighten the nut to 140 Nm. 140 N•m Notice: three types of packed disks are used; to assemble them, see the diagram below. First fit in one of the two disks (1) with the larger fric- tion cells and a plain disk (3).
  • Page 72 Crankcase Fit in the dish pusher, the six spring holders, the plates, the springs, the self-centring washers and the screws; tighten the screws to the prescribed torque in a criss-cross pattern. - 10 -...
  • Page 73 Crankcase Finally, take a gauge and check if the measured dis- tance between the outer surface of the disk pusher and the packed disk is consistently 5 ± 0.1 mm in the four holes. - 11 -...

  • Page 74: Gear And Gear Control

    Crankcase GEAR AND GEAR CONTROL Tightening torque N·m 25 (M8) Thread blockers Medium Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 12 -...
  • Page 75 Crankcase Disassmbling gear group Remove the clutch following the instructions in the rel- ative paragraph. Remove the clutch rod from the clutch end. Remove the 6 tightening screws from the gear cap. Using a rubber hammer, delicately beat on the primary shaft from the clutch end holding a hand on the gear cap until it moves from the bedplate.
  • Page 76 Crankcase Gear command Disassemble the gear command group following the order shown in the figure. Place the various components in an orderly way so as to facilitate reassem- bling. Check each component for wear of irregular traces on its surface. Carefully check the following compo- nents.
  • Page 77 Crankcase Primary and secondary shaft Check the two shafts separate- ly so as to avoid confusion of similar components. Place the components in such a way as to facilitate the correct positioning dur- ing reassembly. - 15 -...
  • Page 78 Crankcase Gear group revision In order to carry out the following procedure the follow- ing special tool is necessary: Motor simulation utensil n° 8A0094792 Disassemble the gear group from the motor and reassemble it on the special utensil n° 8A0094792 motor simulator being careful to tighten the pinion fix- ing nuts with the separator that simulates the clutch hub.
  • Page 79 Crankcase Installation To execute this operation you need the following special tools: n° 8A0094792 gearbox tool Reassembly the various parts by acting in the opposite way. Install the 2 shafts on the n° 8A0094792 engine simulation tool. Install a shift pedal and check the gear box is correctly working.
  • Page 80 Crankcase All the gears must be inserted and unin- serted without stumbling. In case of stumbling, verify that the axial play has been correctly restored. With a thick meter verify that each gear- ing, once inserted presents a fork-pit play equal to 0,2 ÷ 0,3 mm placing it on both ends of the coupling.

  • Page 81: Water Pump

    Crankcase WATER PUMP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 19 -...
  • Page 82 Crankcase Removing water pump Work with cold motor. Drain liquid. A)Loosen the clamp and remove the coupling from the cylinder group,being careful not to damage it. B)Remove the screws (1) which fasten the pump body to the bedplate. C) Slide the pump out of the bedplate. Scomposizione organi pompa acqua After having extracted the pump from the bedplate disassemble the pump as...
  • Page 83 Crankcase A)Heat the pump body (1) at 120°C. B)Remove the 2nd bearing (7). C)Remove the two oil seals (8) and (9). Revision of water pump pieces Verify that each component does not show any wear signs. In particular verify the flowness of the bearings and the O-Ring condition Verify that the impeller does not show signs of giving away or slits.
  • Page 84 Crankcase Reassembling water pump parts During the following procedure use the nec- essary precautions so as not to get burned A)Position pump casing (1) on the special tool to allow the insertion of the shaft and then heat it to 120°C. B)Fit the oil seal on the engine side (8).
  • Page 85 Crankcase Water pump reassembly A)Insert the pump on the bedplate being very careful not to damage the O-Ring on the pump body B)Insert the screws (1) which fix the pump body onto the bedplate C)Install the coupling with its clamp onto the cylinder group, being careful not to damage it.

  • Page 86: Starting

    Crankcase STARTING Tightening torque N·m Thread blockers medium strong medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 24 -...
  • Page 87 Crankcase Free wheel starting Remove the clutch and gear indicated in the relative paragraphs. Slide out the intermediate starting gear pin, first disas- semble the pin-blockage plate. Slide the intermediate gear. Slide the alternator flange and generator shaft out. If necessary disassemble the male torsion from the generator using tool 800094794 to unscrew the nut.

  • Page 88: Engine Block

    Crankcase ENGINE BLOCK Tightening torque N·m 10+60° Thread blockers Medium Medium Medium Medium See text. Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 26 -...

  • Page 89: Covers

    Crankcase COVERS Tightening torque N·m Thread blockers Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 27 -...
  • Page 90 Crankcase Oil cup 10 N•m Remove the oil cup by means of the 6 mm tightening screws. Always substitute the gasket during reassembly. Check to be sure that the oil inlet filter is integral with no cracks or slits; clean it with compressed air at a low pressure blown from the inside towards the outside.
  • Page 91 Crankcase Disassembly Remove the oil filter and the heat exchanger with rela- tive bearing. Remove as follows as indicated in the relative para- graphs: A) The head B) The cylinder group C) The pistons D) The clutch E) The gear Remove: F) The size 6 screws including the one for the blow-by cap.
  • Page 92 Crankcase H)Separate the two carters (1 and 2) by manipulating the protrusions. I) If necessary remove the bearings (3). L) Slide the motor shaft out. In the event that the bushings should be temporarily removed (4) it is a good idea to identify the bearing number and its carter with a number using a marker.
  • Page 93 Crankcase Revision Once you have disassembled the motor shaft and in case there should be any doubt substitute the bench bushings as well as the connecting rod. Verify the motor shaft wear tolerance. The function play of the bench bearings must be between 0,012÷0,038 mm.
  • Page 94 Crankcase Laterally lubricate the nr. 5 support as it carries out the function of the motor shaft centering. Put the new cap on the right side after having put the silicone type paste on the cap’s surface, between cap and carter bearing. Assembly the motor shaft.
  • Page 95 Crankcase Verify with a thick meter that the motor shaft has an axial play of 0,2 mm as regards the bench bearings. In case there should be different values contact the manufacturer. Reassemble the bearing on the inferior semi carter with the locks facing each other and turned inward the bedplate.
  • Page 96 Crankcase Insert the 12 size 8 screws manually manipulating them thus tightening them to the coupling at 25 N·m. Insert the remaining M6 screws manually manipulating them and tighten them to the coupling at 10 N·m. Tighten all the screws inversely to the order they were disassembled.
  • Page 97 Crankcase Disassembling connecting rod Remove the driveshaft following the suggested proce- dure. Position the shaft with the connecting rod downwards. Work on each connecting rod separately. Loosen the two screws that tighten the cap of the con- necting rod and the head of the rod. Remove the two screws that sustain the connecting rod stem.
  • Page 98 Crankcase Check and placement of distribution chain At each motor revision verify the wear state of each transmission distribution component. If the gear teeth appear to be very worn substitute each piece. Substitute the chain at the mileage foreseen in the main- tenance schedule (Page 3, Section B).

  • Page 99: Mainshaft

    Crankcase MAINSHAFT Tightening torque N·m Thread blockers Medium See tightening notes Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 37 -...
  • Page 100 Crankcase - 38 -...
  • Page 101 Lubrication SECTION Revision 0 - 1 -...
  • Page 102 Lubrication SUMMARY OIL PUMP ..............................PAGE 3 SUBSTITUTE OL FILTER.......................... PAGE 5 - 2 -...

  • Page 103: Oil Pump

    Lubrication OIL PUMP Tightening torque N·m Thread blockers Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 104 Lubrication Remove the clutch and the gear as described in the relative paragraphs. Remove the seeger and the oil pump gearing. Remove the 3 tightening screws. Push the oil pump shaft from the gear end and slide the oil pump body from the clutch end. To disassemble the oil pump remove the external screws.
  • Page 105 Take an oil filter out of (black version) the new motor oil filter kit (Part code n° 8000A3702) of new furnishing. Exclusively us MV Agusta components. Take the new motor oil filter gasket out of the oil filter kit (Part code N° 8000A3702) and fit it on the filter as shown in the figure.
  • Page 106 Lubrication After completing the operation, ensure that the dis- tance between the screw and the clamp fastener is 1 to 1.5 mm (see figure). Run the engine for 3 minutes and then check that no oil is leaking from the filter. WARNING: Do not use the oil filter as a grip- ping or support point.
  • Page 107 Electrical components SECTION Revision 0 - 1 -...
  • Page 108 Electrical components SUMMARY ELECTRICAL COMPONENTS ........................PAGE 3 - 2 -...

  • Page 109: Electrical Components

    Electrical components ELECTRICAL COMPONENTS Tightening torque N·m Thread blockers Medium Medium Apply motor oil Apply silicone sealing NO OIL Do not apply neither oil nor other types of substances Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 110 Electrical components Remove the pick-up from the phonic wheel. 25 N•m Alternator - Removal: Working on the left side of the motor, remove the three alternators and the stiffening stirrup tightening nuts. Slide the alternator out being careful not to let the rubber torsions fall .
  • Page 111 Tightening torques SECTION Revision 0 - 1 -...
  • Page 112 Tightening torques SUMMARY TIGHTENING TORQUES ..........................PAGE 3 - 2 -...
  • Page 113 Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION N·m Thread blockers HEAD Camshaft and gear screws strong Sliding block distribution screws medium Stand screws Valve cap and reed cover screws Head nuts 50 (35+15) Chain tightening screws Phase sensor screw Spark plug coil screw Chain tightening cap CLUTCH Clutch nut...
  • Page 114 Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION N·m Thread blockers CRANKCASE Clutch cap M6 screws M6 bearing clamp screw medium M6 screws M8 x 95mm torque screws 10 + 60° M8 torque screws Bearing exchange screws Exchanger screw CONNECTING ROD Cap screws (*) See fitting notes - 4 -...
  • Page 115 Service tools SECTION REVISION 0 - 1 -...
  • Page 116 Service tools - 2 -...
  • Page 117 Service tools Code Q.ty Note F4 312 RR 1078 DESCRIPTION 8A0094792 • CHANGE GEAR ASSEMBLY TOOL 800086119 • DOWELBUSH 8000A1087 • BEARING 800098405 • BEARING 800087300 • BEARING 8A00A5394 • DIAGNOSTIC SOFTWARE 8000A3406 • PISTON PROJECTION MEASURING TOOL 800094797 • HEAD COVER SHAPED PLATE 800094795 •...
  • Page 118 Service tools - 4 -...
  • Page 119 Service tools Code Q.ty Note F4 312 RR 1078 DESCRIPTION 8000A2281 • TIMING CHAIN CUTTING TOOL 8000A2280 • TIMING CHAIN MOUNTING TOOL 800079015 • CLUTCH BLOCKING TOOL 800095318 • PAD FOR EXHAUST VALVE SEAT 800095319 • PAD FOR INTAKE VALVE SEAT - 5 -...
  • Page 120 Service tools - 6 -...
  • Page 121 Analytical index SECTION REVISION 0...
  • Page 122 Analytical index ANALYTICAL INDEX WORKSHOP MANUAL F4 312RR 1078 Sez. A - General description Glossary and symbols ......A- 4 How to consult this manual ....A- 3 Index ............A- 9 Observations ......... A- 9 Operative technical specifications ..A- 10 Right hand and left hand standard ..
  • Page 124 MV AGUSTA S.p.A. - Servizio Assistenza Tecnica Via Giovanni Macchi, 144 - 21100 Varese (VA) ITALY Tel. (Italia) 800.36.44.06 - (estero) ++39 0332 254.712 Fax ++39 0332 329.379 - sito web “www.mvagusta.it" Part. N. 8A00B2576 Edizione N° 1...

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